RU230872U1 - Generator Set Start Controller - Google Patents

Abstract

The utility model relates to devices for power supply of electric networks and distribution of electric energy, more precisely to devices for emergency or backup power supply with automatic switching from a normal source to a backup source (automatic input reserve devices, hereinafter referred to as ATS devices), and even more precisely to devices used to start an internal combustion engine (hereinafter referred to as ICE), which serves as a drive for a reserve electric generator. A controller for starting a generator set is proposed, connected to a battery and containing a central processor, which, in order to ensure trouble-free starting of the engine of the set, including after a long period of inactivity, additionally contains a power control bus with the ability to connect control signals to it, as well as a normally open key included in the controller power supply circuit, controlled from the power control bus. In this case, a connection is introduced between the main processor and the power control bus, ensuring that after the main processor is turned on, a control signal from the main processor is supplied and constantly maintained to the power control bus. This prevents the battery from being discharged by a constantly turned on start controller. A solid-state or electromechanical relay, as well as a field-effect or MOSFET transistor, can be used as a key.

Description

The utility model relates to devices for power supply of electric networks and distribution of electric energy, more precisely to devices for emergency or backup power supply with automatic switching from a normal source to a backup source (automatic input reserve devices, hereinafter referred to as ATS devices), and even more precisely to devices used to start an internal combustion engine (hereinafter referred to as ICE), which serves as a drive for a reserve electric generator. In the prior art, such devices are usually called generator start controllers or, more correctly, ICE start control controllers.

In cases where the backup source of the ATS device is an electric generator driven by an internal combustion engine (hereinafter referred to as a generator set), and emergency shutdowns occur infrequently (once a week or once a month), the problem of the generator set's readiness for starting arises, primarily the problem of its battery's ability to provide power to the internal combustion engine starter at the proper level.

The SmartGen HGM1620N/NC/CAN controller is known for controlling the start of a diesel generator set, connected to a battery and containing a main processor to which control signal sources and control objects are connected [https://gen-newenergy.ru/netcat_files/319/751/Instruktsiya_po__expluatatsii_i_obsluzhivaniyu_TSS.pdf, p. 25, accessed 02/26/2024].

Even in standby mode, the controller consumes little energy from the battery. Since emergency shutdowns are rare with good networks, it may turn out that by the time of the next shutdown, the battery is so discharged that it cannot reliably start the diesel engine, especially in cold weather. To recharge the battery during downtime, you need to have an auxiliary (buffer) charger, which, in turn, requires a constant connection to the power grid. This is not always possible, in particular if the facility is located in a forest or in remote, newly developed areas. In addition, a constant buffer charge reduces the life of the battery, or rather reduces its ability to deliver high currents required to crank the starter.

The closest to the proposed one in terms of technical essence and the achieved result is the controller (block) of automatic start of the generator unit BAZG-1, connected to the battery and containing the main processor, to which the sources of control signals and control objects are connected [http://www.oaomzemi.ru/catalog_position_138692.html, accessed 06.02.2024]. The known controller has the same drawback as the previous analogue: it is constantly on and even in idle (standby) mode consumes energy from the battery, gradually discharging it.

The objective of this utility model is to increase such an indicator of generator unit reliability as failure-free starting of the internal combustion engine.

The technical result of using the proposed utility model consists in increasing the reliability of the generator unit controlled by the proposed controller by ensuring a trouble-free start of the internal combustion engine, including after a long period of inactivity, by preventing the battery from being discharged by the constantly switched-on start controller.

The specified technical result is achieved by the fact that a power control bus with the possibility of connecting control signals to it, as well as a key included in the power supply circuit of the controller, controlled from the power control bus, is additionally introduced into the known controller for starting a generator set, connected to a battery and containing a central processor; in addition, a connection is introduced between the main processor and the power control bus, ensuring, after switching on the main processor, the supply and constant maintenance of a control signal from the main processor to the power control bus.

In addition, the controller additionally contains converters connected to the power control bus for incoming external control signals to the key control signal level.

In addition, an electronic relay is used as a controlled key in the controller.

In addition, an electromechanical relay is used as a controlled key in the controller.

In addition, a transistor is used as a controlled key in the controller.

By introducing a power control bus into the controller (circuit), to which control signals can be connected, the receipt of any of which requires starting the internal combustion engine and generator unit, as well as a key controlled from the power control bus, the reliability of the generator unit controlled by the proposed controller is increased, since the battery, which is idle, does not discharge, spending energy on powering the disconnected controller. At the same time, the ability to turn on the power supply of the controller almost instantly is preserved.

By introducing a connection between the main processor and the power control bus, which ensures that after the main processor is switched on, a control signal is supplied and continuously maintained from the main processor to the power control bus, a reliable start of the generator set is achieved, even if the control signals are of the nature of a short-term single pulse.

Additionally, converters of incoming external control signals to the key control signal level connected to the power control bus allow control signals of different amplitudes and durations to be supplied to the controller.

By using an electronic relay as a controlled key in the controller, the control power is reduced to a minimum and the reliability of the key element is increased.

By using an electromechanical relay as a controlled key in the controller, the device's resistance to various types of interference is increased.

By using a transistor as a controlled key in the controller, the highest key response speed is achieved, which is most valuable when ignition pulses from gasoline internal combustion engines are used as a signal to turn on the controller.

The essence of the utility model is explained by a drawing, which shows a symbolic image of the controller elements related to the declared technical solution.

The basis of the controller 1 (circled with a dashed line) for starting the generator set is the main processor 2, which receives power from the converter 3, connected via a normally open (open) key 4 controlled by an electrical signal to the battery 5. The battery can be the starter battery of the internal combustion engine or a separate battery for its own needs. Converter 3, conditionally shown in the drawing as the only one, in specific cases can be a group of converters with different output parameters necessary to supply power to all consumers of the controller.

The controlled key, or key element 4, is normally open or normally open, and can be either an electromechanical relay or a solid-state relay. Electromechanical relays do not have leakage currents, are not afraid of static and high voltage, as well as strong electromagnetic fields and interference, and are not afraid of polarity reversal, which is dangerous for solid-state keys. They are advisable to use in military-grade controllers. The response speed of electronic relays, including optocoupler and key transistor, is higher than that of electromechanical relays. When using a field or MOSFET transistor as a key element, the highest response speed and the ability to operate from very short-term pulses are achieved when using ignition pulses of gasoline internal combustion engines as a source of the control signal.

The relay winding or the starting electrode of the solid-state switch are connected to the controller power supply control bus 6. All sources of control signals used to start the ICE of the installation are also connected to this bus. The control signals are shown in the drawing as single lines with arrows, and the power supply circuits are shown as double lines without arrows.

Key 4 can be single-pole, since in almost all cases one of the battery poles and one of the input poles of converter 3 are constantly connected to the ground of the installation.

As an example, the drawing shows six sources of control signals, the appearance of which on the power control bus 6 causes the opening of switch 4, namely:

- 7 - signal of the presence of 220 V voltage at the generator output;

- 8 - pulses from the ignition coil of the internal combustion engine;

- 9 - starter switch signal;

- 10 - signal to start the internal combustion engine;

- 11 - signal from manual control buttons;

- 12 - signal from the switched on central processor.

The set of sources may be more or less than those listed, depending on the specific purpose of the controller: a controller specialized only in starting a carburetor ICE may have less, while a universal controller suitable for starting both diesel and carburetor engines may have more.

To turn on the controller directly at the location of the generator set, button 13 can also be used, which bypasses key 4 when pressed.

Auxiliary elements of the controller, such as those used to bring the levels of control signals to a single value, and other logical and measuring elements are not shown in the drawing.

The proposed utility model works as follows.

In the idle state, key 4 is open (closed) and the current consumption from battery 5 does not exceed tens of nanoamps in the case of a solid-state key and is completely absent if the key is an electromechanical relay.

Signals 7-12 are, if necessary, brought to a single level required for opening switch 4 by auxiliary circuit elements of the controller, not shown in the drawing. When any of signals 7-11 arrives at bus 6, it is transmitted to the control input of switch 4, which opens. Through open switch 4, the voltage of battery 5 enters power converter 3, which converts it to the level required by main processor 2 and other consumers of the controller, and supplies it to the main processor and other consumers.

Since some of the control signals may have the character of a short-term single pulse, for example, a signal from pressing a button, the main processor 2, switched on in the manner described above, immediately sends signal 12 to bus 6 and constantly maintains it, thereby maintaining switch 4 in the open state. The same happens with a short-term pressing of button 13, the opening of which no longer turns it off.

After starting the generator set, the battery 5 is recharged and the controller 1 is powered in the usual way from the backup network. When it is necessary to de-energize the controller, the processor removes the signal from the power control bus and the controller is de-energized until any of the signals appears.

The practical experience of year-round operation of the proposed utility model in a generator set with a diesel engine with a capacity of 84 hp (62 kW) of the Mitsudiesel MDN 56 4LT type showed that in 14 cases of its start during the year there was not a single failure to start the engine. The unit was located in an unheated room and had no connection to an external network that could be used to recharge the battery. After a year, testing of the battery used in the unit of the AH Sacred Sun SP12-80 type (12 V, 80 Ah) showed no decrease in its capacity and no increase in self-discharge within the accuracy of measuring these parameters.

Claims (5)

1. A generator start controller connected to a battery and containing a central processor, characterized in that it additionally contains a power control bus with the ability to connect control signals to it, as well as a key included in the controller power supply circuit, controlled from the power control bus; in addition, a connection is introduced between the main processor and the power control bus, ensuring, after the main processor is switched on, the supply and constant maintenance of a control signal from the main processor to the power control bus. 2. The controller according to item 1, characterized in that it additionally contains converters connected to the power control bus for externally incoming control signals to the key control signal level. 3. The controller according to item 1, characterized in that an electronic relay is used as the controlled key. 4. The controller according to item 1, characterized in that an electromechanical relay is used as the controlled key. 5. The controller according to item 1, characterized in that a transistor is used as the controlled key.